Tom Hall-Jones

Temperature Measurement Specialist

With a deep understanding of thermocouples, PT100 resistance temperature detectors (RTDs), and their associated components, I offer comprehensive solutions for a wide range of industries and applications.

Precision Temperature Measurement Specialist: Expertise in Thermocouples, PT100s, and ATEX Sensors

With extensive knowledge and expertise in thermocouples, PT100 resistance temperature detectors (RTDs), and their related accessories, I provide complete, end-to-end temperature measurement solutions tailored to meet the diverse needs of various industries and applications. From sensor selection and installation to cable management and data integration, I offer a comprehensive approach to ensuring accurate, reliable, and efficient temperature monitoring across your organization.

My expertise encompasses the complexities of thermocouple cables, allowing me to optimize signal transmission and ensure the utmost accuracy in temperature measurements.

With a deep understanding of the diverse range of connectors and sealed feedthrough glands available, I excel in selecting and implementing the ideal components for each unique application. By carefully considering factors such as environmental conditions, signal integrity, and mechanical stability, I guarantee reliable and secure connections that withstand the demands of various industrial settings. Whether it’s navigating the challenges of moisture, vibration, or extreme temperatures, my knowledge allows me to deliver robust solutions that maintain the integrity of your temperature measurement system.

Furthermore, my expertise extends to ATEX-certified sensors, enabling me to provide temperature measurement solutions for hazardous areas and explosive atmospheres. By staying up-to-date with the latest industry standards and regulations, I ensure compliance and safety in these critical applications.

With a keen eye for detail and a commitment to delivering high-quality solutions, I collaborate closely with clients to understand their unique temperature measurement challenges. Whether it’s designing custom sensor configurations, troubleshooting complex systems, or providing guidance on installation and maintenance best practices, I am dedicated to optimizing temperature measurement accuracy, reliability, and efficiency.

If you require a trusted partner in temperature measurement, I am confident in my ability to deliver tailored solutions that meet your specific needs. Let's work together to ensure precise and dependable temperature monitoring for your organization.

What is it I can help you with?

Thermocouples

Thermocouples are widely used temperature sensors that consist of two dissimilar metal wires joined together at one end, creating a junction. They operate on the principle of the thermoelectric effect, which states that when two different metals are connected and exposed to a temperature gradient, a voltage is generated that is proportional to the temperature difference between the junction and the reference end.

Key points about thermocouples:

  • Construction: Thermocouples are made by welding or fusing two different metal alloys together at one end, forming a measurement junction. The other end, known as the reference junction or cold junction, is typically connected to a measuring device.
  • Temperature measurement: When the measurement junction is exposed to a temperature to be measured, a voltage (electromotive force or EMF) is generated due to the temperature difference between the measurement junction and the reference junction. This voltage is then interpreted by a measuring device to determine the temperature.
  • Types: Thermocouples are classified by letter designations (e.g., J, K, T, E, N) based on the specific alloys used in their construction. Each type has unique characteristics, such as temperature range, sensitivity, and stability, making them suitable for different applications.
  • Temperature range: Thermocouples can measure temperatures over a wide range, typically from -200°C to +1600°C, depending on the type of thermocouple used.
  • Applications: Thermocouples are used in various industries, including manufacturing, power generation, aerospace, automotive, and scientific research, for temperature measurement and control in processes such as heat treatment, combustion monitoring, and environmental monitoring.


Thermocouples are popular due to their wide temperature range, robustness, relatively low cost, and versatility in application. However, they require careful consideration of factors such as accuracy, stability, and environmental conditions to ensure optimal performance.

RTD Sensors

RTD (Resistance Temperature Detector) sensors are precise temperature measurement devices that operate on the principle of electrical resistance change in a metal with varying temperature. They are known for their excellent accuracy, stability, and repeatability over a wide temperature range.

Key points about RTD sensors:

  1. Construction: RTDs typically consist of a fine wire or a thin film of pure metal, usually platinum, wrapped around or deposited on a ceramic or glass core. The most common type of RTD is the PT100, which has a resistance of 100 ohms at 0°C.
  2. Temperature measurement: As the temperature changes, the electrical resistance of the metal element in the RTD changes in a predictable manner. This resistance change is measured and converted into a temperature reading using a calibration equation specific to the RTD type.
  3. Accuracy and stability: RTDs offer high accuracy, typically between ±0.1°C to ±1°C, depending on the class of the sensor. They also provide excellent stability and repeatability over time, making them suitable for applications requiring precise and consistent measurements.
  4. Temperature range: RTDs can measure temperatures from -200°C to +850°C, depending on the type of metal and construction used.
  5. Response time: RTDs have a slower response time compared to thermocouples due to the thermal mass of the sensor. However, their response time is still relatively fast, and they are suitable for most industrial applications.
  6. Linearity: RTDs exhibit a nearly linear relationship between resistance and temperature over a wide range, simplifying the conversion of resistance to temperature.
  7. Applications: RTDs are used in various industries, including pharmaceutical, food processing, HVAC, and automotive, for applications such as process control, environmental monitoring, and quality assurance.

While RTDs offer excellent accuracy and stability, they are generally more expensive than thermocouples and have a more limited temperature range. They also require a stable power supply for excitation and are more susceptible to self-heating effects, which must be considered during installation and operation.

Thermocouple Cables

Thermocouple cables are specially designed electrical cables used to connect thermocouples to measuring instruments or control systems. These cables are crucial for maintaining the accuracy and reliability of temperature measurements by ensuring correct transmission of the thermoelectric voltage generated by the thermocouple.

What else do we know about  thermocouple cables:

  1. Construction: Thermocouple cables consist of two insulated conductors made from the same alloys as the thermocouple wires they are connecting. The insulation materials are chosen based on the application environment and temperature range.
  2. Extension and compensation cables: There are two main types of thermocouple cables: a. Extension cables: These cables are made from the same alloys as the thermocouple and are used to extend the distance between the thermocouple and the measuring instrument without introducing additional junctions. b. Compensation cables: These cables are made from different alloys that have similar thermoelectric properties to the thermocouple alloys. They are used to connect the thermocouple to the measuring instrument when it is not practical to use extension cables.
  3. Color coding and standards: Thermocouple cables are color-coded according to industry standards (e.g., ANSI or IEC) to identify the thermocouple type and ensure proper connections. Each thermocouple type has a specific color code for the insulation and conductor.
  4. Shielding and grounding: In environments with high electromagnetic interference (EMI), thermocouple cables may incorporate shielding to minimize signal distortion. Proper grounding of the shield is essential to avoid ground loops and ensure accurate measurements.
  5. Temperature ratings: Thermocouple cables are rated for specific temperature ranges based on the insulation materials used. It is essential to select a cable with a temperature rating suitable for the application to ensure reliable performance and longevity.
  6. Termination and connectors: Thermocouple cables can be terminated with various connectors or plugs compatible with the measuring instruments or control systems. Proper termination and the use of high-quality connectors are crucial for maintaining signal integrity.

Thermocouple Connectors

Thermocouple connectors are specialized electrical connectors designed to join thermocouple cables to measuring instruments, control systems, or extension cables while maintaining the integrity of the temperature signal. These connectors provide a reliable and convenient means of connecting and disconnecting thermocouple circuits without compromising accuracy.

Key points about thermocouple connectors:

  1. Materials: Thermocouple connectors are made from materials that are thermoelectrically compatible with the thermocouple alloys to minimize the introduction of additional junctions and maintain the accuracy of the temperature measurement.
  2. Types: There are several types of thermocouple connectors, including: a) Plug and jack connectors: These are the most common type, consisting of a male plug and a female jack. They allow for easy connection and disconnection of thermocouple cables. b) Panel-mount connectors: These connectors are designed to be mounted on a panel or enclosure, providing a fixed connection point for thermocouple cables. c. Miniature connectors: These are smaller versions of plug and jack connectors, used in applications where space is limited or for high-density connections.
  3. Color coding and standards: Thermocouple connectors follow the same color coding standards as thermocouple cables (e.g., ANSI or IEC) to ensure proper identification and connection of thermocouple types.
  4. Temperature ratings: Thermocouple connectors are rated for specific temperature ranges based on the materials used in their construction. It is important to select a connector with a temperature rating suitable for the application environment.
  5. Polarization: Most thermocouple connectors are polarized to ensure proper orientation and connection of the positive and negative thermocouple wires, preventing accidental reversed connections that could lead to inaccurate readings.
  6. Strain relief: Some thermocouple connectors incorporate strain relief features to prevent damage to the thermocouple wires due to mechanical stress or accidental pulling.
  7. Shielding and grounding: In applications with high electromagnetic interference, thermocouple connectors may include provisions for connecting cable shields to ground, minimizing signal distortion.

Selecting the appropriate thermocouple connector is crucial for ensuring reliable and accurate temperature measurements. Factors such as thermocouple type, temperature range, environmental conditions, and mating compatibility with the measuring instrument or control system should be considered when choosing a connector for a specific application

Sealed Feedthroughs

Sealed feedthrough glands, also known as cable glands or sealing glands, are mechanical cable entry devices designed to provide a secure, sealed, and strain-relieved connection point for electrical cables passing through enclosures, walls, or bulkheads. They are used to maintain the integrity of the enclosure, protect against environmental factors, and ensure the reliable operation of electrical systems.

  1. Sealing: The primary function of a sealed feedthrough gland is to create a watertight, dustproof, and sometimes explosion-proof seal around the cable entry point. This is achieved through the use of rubber or elastomeric sealing rings that compress around the cable and the gland body when tightened.
  2. Strain relief: Feedthrough glands provide strain relief for the cable by gripping the cable outer jacket or armor, preventing it from being pulled out of the enclosure and protecting the internal conductors from mechanical stress.
  3. Material selection: Feedthrough glands are available in various materials, such as brass, stainless steel, plastic, or aluminum, to suit different environmental conditions and application requirements.
  4. IP and NEMA ratings: Sealed feedthrough glands are rated according to their level of ingress protection (IP) or NEMA standards, which define their ability to resist the entry of solid particles and liquids. Higher IP or NEMA ratings indicate better protection against environmental factors.
  5. Hazardous area applications: For use in hazardous areas with potentially explosive atmospheres, specialized feedthrough glands with Ex d (flameproof) or Ex e (increased safety) certifications are required to prevent the propagation of explosions and ensure safe operation.
  6. Cable compatibility: Feedthrough glands are designed to accommodate various cable types, sizes, and armor configurations, such as unarmored, braided, or armored cables. Selecting the appropriate gland size and type is crucial for proper sealing and strain relief.
  7. Installation: Proper installation of feedthrough glands is essential to ensure reliable sealing and strain relief. This involves carefully preparing the cable, selecting the correct gland size, and tightening the gland components to the manufacturer’s specified torque values.

Sealed feedthrough glands play a critical role in protecting electrical systems and ensuring the reliability of cable connections in various industrial, commercial, and hazardous area applications. They are commonly used in conjunction with thermocouples, RTDs, and other temperature sensors to provide secure and sealed entry points for sensor cables into process equipment, control panels, or monitoring systems.

Hi, I'm Tom

As a seasoned temperature measurement specialist, I bring a wealth of expertise and a commitment to delivering tailored solutions for your temperature sensing needs. With a deep understanding of thermocouples, PT100 RTDs, thermocouple cables, connectors, and ATEX-certified sensors, I provide comprehensive support to ensure accurate, reliable, and efficient temperature monitoring in your organization.

My services include:

  1. Consultation and Needs Assessment: I work closely with you to understand your unique temperature measurement challenges and requirements, providing expert guidance and recommendations.
  2. Sensor Selection and Implementation: I assist in selecting the most suitable sensors, cables, and connectors for your specific applications, considering factors such as temperature range, accuracy, stability, and environmental conditions.
  3. Custom Solutions: I develop custom sensor configurations and integration strategies to optimize performance and reliability in your system.
  4. Installation and Maintenance Support: I provide guidance on best practices for installation, wiring, and maintenance of temperature measurement components to ensure long-term performance and minimize downtime.
  5. Troubleshooting and Problem-Solving: I offer expert troubleshooting services to identify and resolve issues in your temperature measurement system, ensuring optimal performance and accuracy.
  6. Compliance and Safety: I stay current with industry standards and regulations, particularly for ATEX-certified sensors in hazardous environments, to ensure your temperature measurement solutions meet all necessary compliance and safety requirements.

Whether you’re in manufacturing, power generation, aerospace, automotive, or scientific research, I have the knowledge and experience to deliver precise and dependable temperature measurement solutions tailored to your needs.

Contact me today to discuss how I can support your temperature measurement requirements.